Unitary brick and concrete tilt-up wall sections and molds for producing



May 17, 1966 B. M. TYLER UNITARY BRICK AND CONCRETE TILT-UP WALL SECTIONS AND MOLDS FOR PRODUCING 3 Sheets-Sheet 1 Filed Dec. 24, 1962 BENNIE M.TYLER IN VEN TOR.

May 17, 1966 B. M. TYLER UNITARY BRICK AND CONCRETE TILT-UP WALL SECTIONS AND MOLDS FOR PRODUCING 3 Sheets-Sheet 2 Filed Dec. 24, 1962 BENNIE M. TYLER INVENTOR.

Arr v May 17, 1966 B. M. TYLER 3,251,165

UNITARY BRICK AND CONCRETE TILT-UP WALL SECTIONS AND MOLDS FOR PRODUCING Filed Dec. 24, 1962 3 Sheets-Sheet 5 BENNIE M. TYLER INVENTOR.

United States Patent 3,251,165 UNITARY BRICK AND CUNCRETE TILT-UP WALL SECTIONS AND MULDS FUR PRODUCING Bennie M. Tyler, 6060 NE. 120th Ave, Portland 20, Greg. Filed Dec. 24, 1962, Ser. No. 246,726 2 Claims. (El. 52--293) This invention relates generally to building construction and more particularly to pre-formed wall structures or sections thereof for tilt-up construction.

One of the principal objects of the invention is to provide a wall structure, or sections thereof, of the character described which is formed flatwise within a horizontally disposed frame or mold reposing upon the ground or other suitable support and wherein the wall is formed of cement, concrete, mortar or other cementitious material cast united with building bricks, brick veneer, flagstones, or other suitable aggregates of mineral particles if desired, to provide a strong, durable reinforced wall structure with the outside appearance of a standard brick or stone wall and wherein the bricks or stones may be arranged in stack bond, staggered bond, or in any other desired pattern or configuration.

Another object resides in convenient means for includ ing or embedding reticulated reinforcing material, such as wire mesh or the like, within the wall structure and also the inclusion of insulating material in the form of blocks or slabs of Dylite, styrofoam or other suitable lightweight materal which will effectively resist transfer of moisture or heat or cold, which is an important feature in home or ofiice construction or other areas wherein proper temperatures are to be maintained for comfort.

A further object of the invention is to provide an assembly of wall sections in which the parts are relatively contoured and arranged so that ebuilding may be constructed strongly, efiiciently, and economically without employment of studding or roof rafters.

A further object is to provide a building structure from which the usual skeleton frame may be eliminated.

A still further object is to provide an assembly of fabricated building units coordinated to give strength and rigidity to a building, and portions of which may be preassembled in pre-fabricated units.

The foregoing and other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof and in which:

FIGURE 1 is an elevational view of a building wall comprising integrated wall sections made'in accordance with one form of my invention.

FIGURE 2 is a fragmentary rear elevational view of one of the wall sections.

FIGURE 3 is a fragmentary end elevational view on an enlarged scale taken approximately along the line 3-3 of FIGURE 1.

FIGURE 4 is a top plan view of a pilaster showing means of interconnecting the wall sections therewith and with each other.

FIGURE 5 is a view similar to FIGURE 4 showing a modification thereof.

FIGURE 6 is a plan view of a wall section showing fragments of its component layers of concrete, insulation, wire mesh, and mortar all cast united with an outside facing of building bricks.

FIGURE 7 is a perspective view of a building brick which has been segmented in the course of its manufacture for convenient disintegration into thinness especially adapted for the wall section construction of this inven tion so as to present the outside appearance of a full size brick.

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FIGURE 8 is a fragmentary elevational view of a modified form of two erected and interconnected wall sections.

FIGURE 9 is a perspective view of a typical brick element derived from 'the brick shown in FIGURE 7.

FIGURE 10 is a top plan view of FIGURE 8 showing one form of means for interconnecting the wall sections thereof after erection.

With continuing reference to the drawings wherein like references of character designate like parts and particularly FIGURE 1 thereof, reference numeral 11 indicates generally a wall of a building, made up of sections 2, 3, 4, and 5 which may be of any desired height and width and interconnected by poured cement pilasters indicated generally at 6, 7, and 8 integrated in any suitable manner with a foundation or base 10 of concrete, cement or the like.

The brick components of the wall sections may be arranged in stack bond as shown in wall sections 2 and -5 or in staggered bond as shown in sections 3 and 4. The wall sections may be provided with any desired number of window and door openings indicated at 12 and 13.

In building a wall section in accordance with this invention, the typical brick pieces 25 as shown in FIGURE 9, disintegrated from the brick shown in FIGURE 7, may be conveniently placed within the spaces provided and defined by longitudinal and transverse guide elements 19 and 20, shown in FIGURE 6, with no special skill such as required in conventional brick laying operations. Mortar or other cementitious material is now applied to the spaces between the brick pieces thus placed as aforesaid. Following this, a web of wire mesh 28 or other suitable steel reinforcing means is placed upon the brick pieces. A first layer 30 of concrete or cement is then poured over the wire mesh for cast-bonding it with the brick pieces and the mortar therebetween. To enhance the reinforcing effectiveness of the wire mesh, I have found it desirable to float or lift the wire mesh upwardly into the cement to fully partake of the bonding thereof, and this may be accomplished in several different ways; one for example by engaging the wire mesh with a hook or hooks and pulling it up into the concrete.

Blocks or slabs 31 of insulating material such as Dylite or styrofoam of any desired length and width are then placed upon the first layer of cement or concrete 30. Following this, a final or finishing layer 32 of cement or concrete is poured over the insulating blocks and if desired, a second web of reinforcing mesh (not shown) may be embedded in the final layer of cement or concrete in the same manner of embedding the first web of wire mesh 23 within the first layer of concrete or cement.

As one effective means of further reinforcing the wall section and for securing all of the sections to adjacent pilaster 6-3, I embed reinforcing irons 35 within either layer of cement or concrete 30 or 32 and extend their end portions as at 39 for bonding with the pilasters as the cement is poured to form them in the cross-sectional shape shown in FIGURE 4.

The entire assembly thus far completed is allowed to set for a sufficient length of time to become dry or rigid enough to be tilted up into final wall assembly.

In the erected staggered bond modified form of wall structure shown in FIGURE 8, I dispense with the reinforcing irons 35. The face of the wall across the juncture of the two sections 46-47 is then completed by placing and cementing full length brick pieces 49 within the full length spaces provided by the staggered arrangement of the end brick pieces in one layer relative to those in the next.

Matching steel plates 55 are secured in any suitable manner to or embedded within the wall section material back to the brick facing and are welded as at 56 to pro- J vide solid anchorage of the tops of the wall sections to each other. (See FIG. 10.) Either form of wall section may be secured to the mod1- fied form of pilaster 60 shown in FIGURE by two side angle clips 61-62, a rearward angle clip 63 all secured respectively in any suitable manner, such for instance as by bolts 64 to the pilaster and bolts 65 to the pilaster footing 66, and also by matching steel plates 67 embedded within or secured in any suitable manner to the top of the wall section material back of the brick facing and welded together as at 68 to provide solid anchorage of the tops of the wall sections to each other in the same manner as the walls shown in FIGURES 8 and 10.

The manner of interconnecting the wall sections with each other as shown in FIGURE 8 or with the pilasters as shown in FIGURES 4 and 5, are exemplary of various wall section uniting means which may or may not be conventional in building construction.

Wall sections made in accordance with this invention are adaptable to tilt-wall construction and may be attached or interconnected in many ways making the assembly versatile, yet beautiful and permanent. The walls require little maintenance and receive a low insurance rate, yet.

will demand high loan value which will be retained for many years. The finished wall sections are true and bright and need little or no cleaning. I

The utilization of brick segments having the appearance when laid, of standard building bricks effects a substantial saving in the cost of material. one standard brick economically divided into sections 25 as shown in FIGURES 7 and 9, and cast-united with the concrete wall greatly exceeds the strength and durability of a standard brick wall and presents a pleasing appearance because of the smooth uniform application of mortar between the interstices of the bricks to a uniform depth which produces a uniform shadow line throughout the length and height of the Wall structure.

While I have shown particular forms of embodiment of my invention, I am aware that many minor changes therein will readily suggest themselves to others skilled in the art without departing from the spirit and scope of the invention. Having thus described my invention what I claim as new and desire to protect by Letters Patent is:

1. A building wall comprising,

a plurality of pilasters of poured cementitious material mounted upon ground-engaging footing,

a plurality of wall sections positioned between said pilasters,

each of said wall sections comprising courses of building bricks uniformly spaced relative to each other throughout the length and height of their respective section,

bonding material occupying the interstices between said bricks and cast-uniting them into a solid panel,

a first layer of cementitious material overlying said bricks and cast-united therewith,

alayer of insulating material overlying said layer of cementitious material,

a second layer of cementitious material overlying said insulating material,

reinforcing elements extending through at least one layer of said cementitious material substantially through out the length and height thereof,

means interconnecting said pilasters and wall sections,

said means comprising horizontally disposed vertically spaced-apart reinforcing rods embedded within each of said wall sections and extending outwardly from both ends thereof and embedded within said poured pilaster material, and

a pair of axially-aligned plates embedded within and 7 extending outwardly from the top of adjacent wall In other words,

sections and welded together at their meeting ends into a unitary cap plate,

whereby said wall sections are secured to their respective pilasters by the extended ends of said reinforcing rods embedded therein, and further secured to each other and to the pilasters by said unitary cap plates.

2. A building wall comprising,

a plurality of pilasters of poured cementitious material secured at their bottom end to ground-engaging foota plurality of wall sections positioned between said pilasters,

each of said wall sections comprising courses of building bricks uniformly spaced relative to each other throughout the length and height of their respective section,

bonding material occupying the interstices between said bricks and cast-uniting them intov a solid panel,

a first layer of cementitious material overlying said I bricks and cast-united therewith,

a layer of insulating material overlying said layer of cementitious material,

a second layer of cementitious material overlying said insulating material,

reinforcing elements extending through at least one layer of said cementitious material substantially through-' out the length and height thereof,

means interconnecting said pilasters and wall sections,

said means comprising horizontally disposed vertically spaced-apart reinforcing rods embedded within each of said wall sections and extending outwardly from both ends thereof and embedded within said poured pilaster material,

angle clips securing the bottom end of each of said pilasters to said ground-engaging footing, and

a pair of axially-aligned plates embedded within and extending outwardly from the top of adjacent wall sections and welded together at their meeting ends into a unitary cap plate,

whereby said wall sections are secured to their respective pilasters by the extended ends of said reinforcing rod embedded therein further secured to each other and to the pilasters by said unitary cap plates with the pilasters secured to the ground-engaging footing by said angle clips.

References Cited by the Examiner UNITED STATES PATENTS OTHER REFERENCES Construction Methods: pp. -102, August 1956.

FMNK L. ABBOTT, Primary Examiner.

HENRY C. SUTHERLAND, Examiner. 

1. A BUILDING WALL COMPRISING, A PLURALITY OF PILASTERS OF POURED CEMENTITIOUS MATERIAL MOUNTED UPON GROUND-ENGAGING FOOTING, A PLURALITY OF WALL SECTIONS POSITIONED BETWEEN SAID PILASTERS, EACH OF SAID WALL SECTIONS COMPRISING COURSES OF BUILDING BRICKS UNIFORMLY SPACED RELATIVE TO EACH OTHER THROUGHOUT THE LENGTH AND HEIGHT OF THEIR RESPECTIVE SECTION, BONDING MATERIAL OCCUPYING THE INTERSTICES BETWEEN SAID BRICKS AND CAST-UNITING THEM INTO A SOLID PANEL, A FIRST LAYER OF CEMENTITIOUS MATERIAL OVERLYING SAID BRICKS AND CAST-UNITED THEREWITH, A LAYER OF INSULATING MATERIAL OVERLYING SAID LAYER OF CEMENTITIOUS MATERIAL, A SECOND LAYER OF CEMENTITIOUS MATERIAL OVERLYING SAID INSULATING MATERIAL, REINFORCING ELEMENTS EXTENDING THROUGH AT LEAST ONE LAYER OF SAID CEMENTITIOUS MATERIAL SUBSTANTIALLY THROUGHOUT THE LENGTH AND HEIGHT THEREOF, MEANS INTERCONNECTING SAID PILASTERS AND WALL SECTIONS, SAID MEANS COMPRISING HORIZONTALLY DISPOSED VERTICALLY SPACED-APART REINFORCING RODS EMBEDDED WITHIN EACH OF SAID WALL SECTIONS AND EXTENDING OUTWARDLY FROM BOTH ENDS THEREOF AND EMBEDDED WITHIN SAID POURED PILASTER MATERIAL, AND A PAIR OF AXIALLY-ALIGNED PLATES EMBEDDED WITHIN AND EXTENDING OUTWARDLY FROM THE TOP OF ADJACENT WALL SECTIONS AND WELDED TOGETHER AT THEIR MEETING ENDS INTO A UNITARY CAP PLATE, WHEREBY SAID WALL SECTIONS ARE SECURED TO THEIR RESPECTIVE PILASTERS BY THE EXTENDED ENDS OF SAID REINFORCING RODS EMBEDDED THEREIN, AND FURTHER SECURED TO EACH OTHER AND TO THE PILASTERS BY SAID UNITARY CAP PLATES. 